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EP2708668B1 - Method for producing a flame retardant insulating element, insulating element and use of an insulating element - Google Patents

Method for producing a flame retardant insulating element, insulating element and use of an insulating element Download PDF

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Publication number
EP2708668B1
EP2708668B1 EP12184184.5A EP12184184A EP2708668B1 EP 2708668 B1 EP2708668 B1 EP 2708668B1 EP 12184184 A EP12184184 A EP 12184184A EP 2708668 B1 EP2708668 B1 EP 2708668B1
Authority
EP
European Patent Office
Prior art keywords
polystyrene particles
binder
flame retardant
weight
foamable
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Application number
EP12184184.5A
Other languages
German (de)
French (fr)
Other versions
EP2708668A1 (en
Inventor
Martin Hitzler
Eva Kohler
Andreas Weier
Robert Isele
Gerald Burgeth
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Sto SE and Co KGaA
Original Assignee
Sto SE and Co KGaA
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Sto SE and Co KGaA filed Critical Sto SE and Co KGaA
Priority to DK12184184.5T priority Critical patent/DK2708668T3/en
Priority to EP12184184.5A priority patent/EP2708668B1/en
Priority to PL12184184T priority patent/PL2708668T3/en
Publication of EP2708668A1 publication Critical patent/EP2708668A1/en
Application granted granted Critical
Publication of EP2708668B1 publication Critical patent/EP2708668B1/en
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Classifications

    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • C08J9/22—After-treatment of expandable particles; Forming foamed products
    • C08J9/224—Surface treatment
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • C08J9/22—After-treatment of expandable particles; Forming foamed products
    • C08J9/228—Forming foamed products
    • C08J9/236—Forming foamed products using binding agents
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/92—Protection against other undesired influences or dangers
    • E04B1/94—Protection against other undesired influences or dangers against fire
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2325/00—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an aromatic carbocyclic ring; Derivatives of such polymers
    • C08J2325/02—Homopolymers or copolymers of hydrocarbons
    • C08J2325/04—Homopolymers or copolymers of styrene
    • C08J2325/06—Polystyrene

Definitions

  • the invention relates to a method for producing a flame-retardant insulating element with the features of the preamble of claim 1. Furthermore, the invention relates to an insulating element and a use of an insulating element produced by a method according to the invention.
  • a fire-retardant polystyrene foam is known, which on the one hand have an improved fire behavior and on the other hand should not show any deterioration of its original properties.
  • the polystyrene foam should continue to have a low water permeability, high water resistance, very good thermal insulation and sound insulation properties and high mechanical strength at the same time low weight or low density.
  • the proportion of polystyrene particles is 20-75 wt .-% based on the total weight of the composition consisting of polystyrene particles, intumescent material and binder. This means that the polystyrene particle content may be significantly reduced. This must inevitably result in a change in the thermal insulation properties of an insulating element produced therefrom, if the missing polystyrene particles are not replaced by equivalent insulating materials. In addition, in order to continue to ensure the mechanical stability of the foam molding, the binder content must be increased. The high binder content in turn requires the use of a non-combustible binder.
  • foams based on styrene polymers which contain 5-50% by weight of expandable hexagonal graphite as flame retardant are known.
  • the expandable graphite can be applied to the prefoamed particles of the styrene polymer or added to the unfoamed styrene polymer.
  • a flame-retardant foam plastic containing an intumescent material which may additionally comprise an activator and a binder.
  • the object of the binder is to coat the particles of the actual flame retardant with a film to prevent the escape of gases.
  • the ingredients of the intumescent material are mixed with water, dried and ground into powder to subsequently add the powder to the other starting materials.
  • the present invention seeks to provide a method for producing a flame-retardant, polystyrene particles-containing insulating element, on the one hand has a comparison with conventional polystyrene foam boards fire safety improved fire protection and on the other hand excellent thermal insulation properties. At the same time an insulating element to be created with a high mechanical stability.
  • Foamable and / or prefoamed polystyrene particles are used in the process proposed for the production of a flame-retardant insulating element, of which at least one part is coated before being filled into a mold and sintered.
  • the foamable and / or prefoamed polystyrene particles are at least partially coated with an organic binder and with at least one flame retardant, wherein binders and flame retardants are used in powder form and wherein the foamable and / or prefoamed polystyrene coated with binder and flame retardant Particles in one Form are entered and sintered with the addition of heat, so that the binder softens and causes an additional sticking of the solids.
  • In powder form is intended to mean that "dry” starting materials or solids are used for coating the foamable and / or prefoamed polystyrene particles.
  • the pulverulent coating compositions are brought into contact with the foamable and / or prefoamed polystyrene particles, wherein the surface roughness of the foamable and / or prefoamed polystyrene particles already brings about adhesion of the coating compositions.
  • the powdery coating can be applied to both foamable and prefoamed polystyrene particles.
  • Foamable polystyrene particles are generally referred to as polystyrene beads, that is to say polystyrene granules which have not yet been subjected to a prefoaming process. These are first mixed with powdered binder and flame retardant and then prefoamed. The coating with binder and flame retardant is preferably carried out during the pre-expansion, by adding the heat, the binder is made to soften. The expansion of the polystyrene particles during prefoaming and the movement of the polystyrene particles in the pre-foaming container cause the softened binder to settle around the particles and bind the flame retardant to the particles.
  • prefoamed polystyrene particles so-called polystyrene beads
  • binder and flame retardant in powder form and used for the further production of a flame-retardant insulating element.
  • foamable polystyrene particles When foamable polystyrene particles are used, they are preferably prefoamed after mixing with the coating compositions before they are introduced into a mold and sintered. Accordingly, coated prefoamed polystyrene particles enter the mold, regardless of whether foamable or prefoamed polystyrene particles are used as starting materials. In contrast to coated prefoamed polystyrene particles, which were first prefoamed and then coated, the former generally have improved adhesion of the flame retardant to the polystyrene particles.
  • the pulverulent coating agents in particular the flame retardant, which initially adhere only on the surface, penetrate deep into the surface of the expanding polystyrene particles.
  • the moisture that occurs in this case also causes sticking of the originally "dry" starting materials.
  • the steam used as the heating medium leads to a softening of the binder, especially if it is a thermoplastic binder.
  • the softening and then curing binder then forms a matrix additionally binding the flame retardant.
  • the improved adhesion of the flame retardant to the polystyrene particles ensures that there is no segregation of the starting materials in the mold.
  • binders and flame retardants are permanently incorporated into the polystyrene particle foam.
  • the prefoaming process can be carried out continuously or discontinuously. If prefoaming takes place in a stirrer or mixer, the movement contributes to a uniform distribution of the binder and the flame retardant.
  • the formulation should also mean that, alternatively or additionally, the coating with binder and flame retardant can only be applied partially. In this case, "at least partially coated” means that a part of the polystyrene particles need not be coated over the entire surface, but may also have uncoated surface areas.
  • the proportion of uncoated and / or only partially coated polystyrene particles promotes a bonding of the particles to one another, as they merge together during sintering, as in the case of the production of conventional polystyrene rigid foam. As a result, a high mechanical stability of the molding produced in this way is maintained. Furthermore, in this way the binder content is reduced.
  • the low binder content allows the use of an organic binder, which is combustible compared to inorganic binders, but it has an increased binding power. This has a particularly positive effect on the binding of the flame retardant to the polystyrene particles.
  • a flame retardant is used to coat the prefoamed polystyrene particles, which forms an ablative or intumescent protective layer in the event of fire.
  • an ablative protective layer is understood to mean a non-flammable protective layer which provides "passive" fire resistance.
  • An intumescent protective layer is understood to mean a protective layer which forms an insulating protective layer only in the event of fire by foaming and accordingly provides "active" fire resistance.
  • water-releasing "cooling" flame retardants can be used, for example, metal hydroxides, alkali metal silicates and hydrates of metal salts or oxides, which increased at Discharge temperatures chemically or physically bound water, but otherwise present as a "dry” powder. Corresponding flame retardants are well known and are offered by various manufacturers.
  • expanded graphite is used as a flame retardant.
  • the flame-resistant equipment of the coating is significantly improved by the incorporation of expanded graphite.
  • expanded graphite denotes a synthetically produced product group of natural graphite and expandable S and / or N compounds which are incorporated into the layer structure of the graphite. The latter expand under the influence of heat, creating an active fire barrier. The bloom rate can be up to several hundred times the original volume of expandable graphite.
  • organic binder it is further preferred to use a dispersion powder, for example a dispersion powder based on acrylate, styrene acrylate, vinyl acetate, vinyl acetate-ethylene and / or vinyl chloride, for coating the polystyrene particles.
  • a dispersion powder for example a dispersion powder based on acrylate, styrene acrylate, vinyl acetate, vinyl acetate-ethylene and / or vinyl chloride, for coating the polystyrene particles.
  • the low binder content allows the use of organic and thus combustible binder.
  • Organic binders have an increased binding force compared to inorganic, non-combustible binders, so that the binder content can be kept low.
  • the use of a thermoplastic binder promotes adhesion of the coating compositions with one another and with the polystyrene particles when they are prefoamed and / or sintered with the addition of heat.
  • foamable polystyrene particles ie not yet prefoamed polystyrene beads
  • foamable polystyrene particles ie not yet prefoamed polystyrene beads
  • the mixing of the starting materials can also take place only in Vorbululent binder and flame retardant and then prefoamed.
  • the mixing of the starting materials can also take place only in Vorbulum inherenter and / or during the pre-expansion.
  • Prefoaming process improves the adhesion of the binder and the flame retardant to the polystyrene particles as the binder softens and binds the flame retardant to the surface of the polystyrene particles.
  • the softened binder spreads substantially uniformly on the surface of the polystyrene particles, so that in this way a largely uniform coating of the particles with flame retardants is guaranteed. Because the flame retardant adheres in particular to the softened binder.
  • the advantageous movement of the starting materials can be effected in that they are stirred during pre-foaming at the same time.
  • the process of mixing can at the same time effect the coating of the polystyrene particles.
  • mixing or coating can also take place during pre-foaming.
  • the operations of mixing, coating and pre-foaming may coincide or disintegrate. This applies both with regard to the use of foamable and prefoamed polystyrene particles.
  • prefoamed polystyrene particles are already used and mixed with pulverulent binder and flame retardant.
  • pre-expanded polystyrene particles can be used, which still have a certain residual moisture from pre-foaming.
  • the powdery coating compositions do not adhere to them solely via the surface roughness of the particles, but are also bound by the residual moisture contained in the particles.
  • the already pre-expanded polystyrene particles can be subjected to a further pre-foaming process in which the adhering binder softens and binds the flame retardant to the polystyrene particles.
  • all starting materials "dry” (apart from any residual moisture present in the prefoamed polystyrene particles) are first of all combined and intimately mixed, the mixing taking place in a pre-foaming container and / or during prefoaming.
  • the powdery coating agents deposited on the surface of the polystyrene particles are bound to the polystyrene particles by prefoaming and / or softening the binder.
  • the polystyrene particles may be completely or only partially coated with binder and flame retardant after mixing and pre-foaming.
  • the powdery coating compositions can also be brought into contact with the polystyrene particles by pre-foaming or by sprinkling or the like, which are then subsequently prefoamed.
  • the foamable and / or pre-expanded polystyrene particles after being coated with binder and flame retardant, are introduced into a mold and sintered with the addition of pressure and heat.
  • the repeated foaming and welding of the polystyrene particles ensures that the flame retardant is firmly bound in the polystyrene particle foam.
  • the binder also contributes to this, since it softens with the addition of heat and causes an additional sticking of the solids.
  • foamable polystyrene particles which are coated with binder and flame retardant prior to sintering
  • the intermediate step of pre-foaming can also be dispensed with, so that these are subjected to only one foaming process.
  • the foamable and / or prefoamed polystyrene particles coated with binder and flame retardant are admixed with uncoated polystyrene particles before being introduced into a mold.
  • the addition of uncoated polystyrene particles - as well as the admixture or exclusive use of only partially coated polystyrene particles - promotes a fusion of the polystyrene particles together.
  • the melting or sintering effects a stable bonding of the polystyrene particles to one another, so that an insulating element produced in this way has a high mechanical strength.
  • the proportion of uncoated polystyrene particles 0 to 99 vol .-%, preferably 25 to 90 vol .-% and particularly preferably 50 to 88 vol .-% based on the total volume of the polystyrene particles used.
  • polystyrene particle foam produced by this process has very good thermal insulation properties - comparable to those of conventional polystyrene foams.
  • the polystyrene particle foam produced by a process according to the invention also has an increased fire resistance.
  • the increased fire resistance is achieved even with a coating with organic combustible binder, since the binder content is relatively low overall.
  • from 30 to 95% by weight of foamable and / or prefoamed polystyrene particles from 0.5 to 67.5% by weight of binder and from 2.5 to 67.5% by weight of flame retardant, are preferred 40 to 90% by weight of polystyrene particles, 2.5 to 55% by weight of binder and 5 to 55% by weight of flame retardant, furthermore preferably 50 to 85% by weight of polystyrene particles, 5 to 35% by weight % Binder and 7.5 to 35 wt .-% flame retardant, based on the total weight of the starting materials used. Since only "dry" starting materials are used, the total weight corresponds to the total dry weight of the starting materials. In order to obtain an insulating material with excellent thermal insulation properties, the proportion by weight of the polystyrene particles is particularly preferably at least 76 wt .-% based on the total weight of the starting materials.
  • the weight ratio of the foamable and / or prefoamed polystyrene particles to the flame retardant is from 0.4 to 38, preferably from 0.75 to 34, more preferably from 1.05 to 20. Tests with correspondingly produced insulating elements have shown that these have a particularly increased fire resistance or reduced tendency to ignite.
  • the coated and / or uncoated polystyrene particles are added to fibers, fillers and / or additives before being introduced into the mold.
  • the addition of fibers, fillers and / or additives can influence the substance-specific properties of the insulating element. For example, by adding fibers, the mechanical strength of the insulating element can be increased.
  • the process according to the invention described above has the advantage that the systems previously used for the production of insulating elements made of polystyrene rigid foam can continue to be used. This means that no new system technology is required, so that the inventive method is inexpensive to carry out. In particular, the known block foam plants and automatic molding machines can be used.
  • an insulating element which has been produced by one of the preceding methods, impermeable to water and permeable to water vapor.
  • Such an insulating element does not absorb water, but does not hinder the diffusion of water vapor. Accordingly, it can be used, in particular, outdoors or in moisture-laden interior spaces as a sound and / or thermal insulation element.
  • the water impermeability of the insulating element is preferably the result of sintering with the addition of pressure and heat, in which the interstices remaining between the particles are isolated from each other. Because during sintering with the addition of pressure and heat, the starting materials are compressed by increasing the pressure in the mold. The pressure can be applied from the outside and / or generated thereby, that the polystyrene particles have the urge to expand. At the same time, the polystyrene particles crowd close to each other and deform in such a way that the gusset volume between the particles is reduced and at the same time isolated.
  • the EPS beads were mixed with a dispersion powder and a flame retardant and then prefoamed with the addition of pressure (1 bar) and heat (100 ° C), with steam as the heating medium.
  • the dispersion powder softened and bound the flame retardant into the binder matrix.
  • the coated and prefoamed EPS beads were dried in a fluid bed dryer (residence time about 15 minutes), with warm air serving as the drying medium. This hardened both the EPS beads, as well as the softened binder.
  • uncoated conventional EPS beads (grain size 3-8 mm, bulk density 0.015-0.016 g / cm 3 ) were added to the coated and prefoamed EPS beads.
  • the mixture was then placed in a mold measuring 30 cm ⁇ 30 cm ⁇ 10 cm and, with the addition of pressure (1 bar) and heat (100 ° C.), again using steam as the heating medium, the shape from top to bottom 10 - Flowed flat over 15 seconds, blocked. After depressurization, the molded article was removed from the mold and dried at room temperature for a period of one week.
  • the molding produced in this way had a thermal conductivity ⁇ according to DIN EN 12667 of 0.0299 W / (mK) and a density p according to DIN EN 1602 of 16.9 kg / m 3 and a tensile strength perpendicular to the plate surface according to DIN EN 1607 of 154 kPa on. Furthermore, the fire behavior of the molded part was tested, wherein the molded part was exposed to a flammable Bunsenbrennerflamme to assess the flammability and the fire behavior. The test procedure showed a significantly reduced thermoplastic melt flow. The formation of a polymer lake was localized. A burning dripping and an independent further burning of the melt were greatly reduced.
  • EPS beads 56% by weight of EPS beads with 12.5% by weight of dispersion powder (based on polyvinyl alcohol) and 31.5% by weight of expandable graphite were mixed and, as described above, prefoamed. 40% by volume of the coated prefoamed EPS beads produced in this way were then mixed homogeneously with 60% by volume of uncoated prefoamed EPS beads and sintered in the block mold as described above and dried.
  • the molded part produced in this way had a thermal conductivity ⁇ according to DIN EN 12667 of 0.0307 W / (mK) and a density p according to DIN EN 1602 of 20.2 kg / m 3 and a tensile strength perpendicular to the plate surface according to DIN EN 1607 of 166 kPa on. Furthermore, the fire behavior of the molded part was tested, wherein the molded part for Assessment of the flammability and the fire behavior of a roaring Bunsenbrennerflamme was exposed. The test procedure did not show thermoplastic melt flow. A burning dripping did not take place. Furthermore, an independent further burning of the test piece after removal of the flame could be completely prevented.
  • the molded part produced in this way had a thermal conductivity ⁇ according to DIN EN 12667 of 0.0297 W / (mK) and a density p according to DIN EN 1602 of 15.8 kg / m 3 and a tensile strength perpendicular to the plate surface according to DIN EN 1607 of 173 kPa on. Furthermore, the fire behavior of the molded part was tested, wherein the molded part was exposed to a flammable Bunsenbrennerflamme to assess the flammability and the fire behavior. The test procedure showed immediate thermoplastic melting with burning dripping which resulted in the formation of a burning polymer lake.
  • An insulating element produced by a process according to the invention accordingly has a significantly improved fire behavior compared to a conventional insulating element made of polystyrene rigid foam (Reference Example). Due to a no longer flowable melt or a greatly reduced flow behavior, the source of the fire remains localized. Especially no burning polymer lake forms. At the same time, the insulating elements produced by a method according to the invention continue to have very good thermal insulation properties and high mechanical strength.

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Description

Die Erfindung betrifft ein Verfahren zur Herstellung eines flammgeschützten Dämmelementes mit den Merkmalen des Oberbegriffs des Anspruchs 1. Ferner betrifft die Erfindung ein Dämmelement sowie eine Verwendung eines nach einem erfindungsgemäßen Verfahren hergestellten Dämmelementes.The invention relates to a method for producing a flame-retardant insulating element with the features of the preamble of claim 1. Furthermore, the invention relates to an insulating element and a use of an insulating element produced by a method according to the invention.

Stand der TechnikState of the art

Bei der Schall- und/oder Wärmedämmung von Gebäudewänden oder -decken finden häufig Hartschaumplatten, insbesondere Polystyrol-Hartschaumplatten, als Dämmelemente Einsatz. Diese weisen zum einen gute Wärmedämmeigenschaften auf und sind zum anderen relativ kostengünstig herstellbar. Zudem sind sie auf der Baustelle einfach zu handhaben, da sie formstabil und wasserunempfindlich sind. Als nachteilig erweist sich jedoch in der Regel das Brandverhalten von Dämmelementen aus einem Hartschaum, welche daher regelmäßig der Baustoffklasse B (brennbare Baustoffe) gemäß DIN 4102-1 zuzuordnen sind.In the sound and / or thermal insulation of building walls or ceilings are often hard foam panels, especially polystyrene foam boards, as insulation elements use. These have, on the one hand, good thermal insulation properties and, on the other hand, can be produced relatively inexpensively. In addition, they are easy to handle on the construction site, since they are dimensionally stable and insensitive to water. As a rule, however, proves the fire behavior of insulating elements of a hard foam, which are therefore regularly classify the building material class B (combustible materials) according to DIN 4102-1.

Aus der WO 2008/145599 A1 ist ein feuerhemmender Polystyrol-Schaumstoff bekannt, welcher zum einen ein verbessertes Brandverhalten aufweisen und zum anderen keine Verschlechterung seiner ursprünglichen Eigenschaften aufweisen soll. Insbesondere soll der Polystyrol-Schaumstoff weiterhin eine geringe Wasserdurchlässigkeit, eine hohe Wasserbeständigkeit, sehr guter Wärmedämm- und Schallschutzeigenschaften sowie eine hohe mechanische Festigkeit bei gleichzeitig geringem Gewicht bzw. geringer Dichte aufweisen. Darüber hinaus soll die Herstellbarkeit des Polystyrol-Schaumstoffs auf den herkömmlichen Anlagen gewährleistet sein, so dass er weiterhin kostengünstig herstellbar ist. Gemäß der Druckschrift werden diese Ziele durch eine Zusammensetzung erreicht, welche expandierte oder expandierbare Polystyrol-Partikel, einen intumeszenten Stoff und einen feuerbeständigen Binder umfasst. Der Anteil der Polystyrol-Partikel beträgt dabei 20-75 Gew.-% bezogen auf das Gesamtgewicht der Zusammensetzung bestehend aus Polystyrol-Partikel, intumeszenter Stoff und Binder. Das heißt, dass der Polystyrol-Partikelanteil unter Umständen deutlich reduziert ist. Dies muss zwangsläufig eine Veränderung der Wärmedämmeigenschaften eines hieraus hergestellten Dämmelementes zur Folge haben, wenn die fehlenden Polystyrol-Partikel nicht durch gleichwertige Dämmstoffe ersetzt werden. Um zudem weiterhin die mechanische Stabilität des Schaumstoffformkörpers zu gewährleisten, muss der Bindemittelanteil erhöht werden. Der hohe Bindemittelanteil wiederum macht den Einsatz eines nicht brennbaren Bindemittels erforderlich. Es ist jedoch allgemein bekannt, dass die Bindekraft nicht brennbarer, in der Regel anorganischer Bindemittel im Vergleich zu organischen Bindemitteln herabgesetzt ist, so dass eher eine Entmischung der Ausgangsstoffe in der Form zu erwarten ist, welche die Qualität des derart hergestellten Schaumstoffformkörpers beeinträchtigt.From the WO 2008/145599 A1 a fire-retardant polystyrene foam is known, which on the one hand have an improved fire behavior and on the other hand should not show any deterioration of its original properties. In particular, the polystyrene foam should continue to have a low water permeability, high water resistance, very good thermal insulation and sound insulation properties and high mechanical strength at the same time low weight or low density. In addition, the should Manufacturability of the polystyrene foam to be ensured on the conventional systems, so that it is still inexpensive to produce. According to the document, these objects are achieved by a composition comprising expanded or expandable polystyrene particles, an intumescent material and a fire-resistant binder. The proportion of polystyrene particles is 20-75 wt .-% based on the total weight of the composition consisting of polystyrene particles, intumescent material and binder. This means that the polystyrene particle content may be significantly reduced. This must inevitably result in a change in the thermal insulation properties of an insulating element produced therefrom, if the missing polystyrene particles are not replaced by equivalent insulating materials. In addition, in order to continue to ensure the mechanical stability of the foam molding, the binder content must be increased. The high binder content in turn requires the use of a non-combustible binder. However, it is well known that the binding power of non-combustible, usually inorganic binder compared to organic binders is reduced, so that rather a segregation of the starting materials is expected in the mold, which affects the quality of the foam molding thus produced.

Aus der EP 0994 145 A1 gehen ferner Schaumstoffe auf Basis von Styrolpolymerisaten hervor, die 5-50 Gew.-% expandierbaren hexagonalen Graphit als Flammschutzmittel enthalten. Der expandierbare Graphit kann hierzu auf die vorgeschäumten Partikel des Styrolpolymerisats aufgebracht oder dem ungeschäumten Styrolpolymerisat zugegeben werden.From the EP 0994 145 A1 Furthermore, foams based on styrene polymers which contain 5-50% by weight of expandable hexagonal graphite as flame retardant are known. For this purpose, the expandable graphite can be applied to the prefoamed particles of the styrene polymer or added to the unfoamed styrene polymer.

Darüber hinaus ist aus der EP 0113 511 A2 ein flammgeschützter Schaumkunststoff bekannt, der ein intumeszentes Material enthält, das zusätzlich einen Aktivator und ein Bindemittel umfassen kann. Die Aufgabe des Bindemittels besteht darin, die Partikel des eigentlichen Flammschutzmittels mit einem Film zu überziehen, um das Entweichen von Gasen zu verhindern. Um dies zu erreichen, werden beispielsweise die Inhaltsstoffe des intumeszenten Materials mit Wasser gemischt, getrocknet und zu Pulver zermahlen, um das Pulver anschließend den anderen Ausgangsstoffen zuzugeben.In addition, from the EP 0113 511 A2 a flame-retardant foam plastic containing an intumescent material which may additionally comprise an activator and a binder. The object of the binder is to coat the particles of the actual flame retardant with a film to prevent the escape of gases. To achieve this, for example the ingredients of the intumescent material are mixed with water, dried and ground into powder to subsequently add the powder to the other starting materials.

Ausgehend von dem vorstehend genannten Stand der Technik liegt der vorliegenden Erfindung die Aufgabe zugrunde, ein Verfahren zur Herstellung eines flammgeschützten, Polystyrol-Partikel enthaltenden Dämmelementes anzugeben, das einerseits ein gegenüber herkömmlichen Polystyrol-Hartschaumplatten aus Brandschutzsicht verbessertes Brandschutzverhalten sowie andererseits hervorragende Wärmedämmeigenschaften aufweist. Zugleich soll ein Dämmelement mit einer hohen mechanischen Stabilität geschaffen werden.Based on the above-mentioned prior art, the present invention seeks to provide a method for producing a flame-retardant, polystyrene particles-containing insulating element, on the one hand has a comparison with conventional polystyrene foam boards fire safety improved fire protection and on the other hand excellent thermal insulation properties. At the same time an insulating element to be created with a high mechanical stability.

Zur Lösung der Aufgaben wird ein Verfahren mit den Merkmalen des Anspruchs 1 vorgeschlagen. Vorteilhafte Weiterbildungen des erfindungsgemäßen Verfahrens sind in den auf Anspruch 1 rückbezogenen Unteransprüchen angegeben. Ferner werden ein Dämmelement sowie eine bevorzugte Verwendung eines nach einem erfindungsgemäßen Verfahren hergestellten Dämmelementes vorgeschlagen.To solve the problems, a method with the features of claim 1 is proposed. Advantageous developments of the method according to the invention are given in the dependent claims on claim 1. Furthermore, an insulating element and a preferred use of an insulating element produced by a method according to the invention are proposed.

Offenbarung der ErfindungDisclosure of the invention

Bei dem zur Herstellung eines flammgeschützten Dämmelementes vorgeschlagenen Verfahren werden schäumbare und/oder vorgeschäumte Polystyrol-Partikel verwendet, von denen zumindest ein Teil vor dem Einfüllen in eine Form und dem Versintern beschichtet werden. Erfindungsgemäß ist vorgesehen, dass die schäumbaren und/oder vorgeschäumten Polystyrol-Partikel zumindest teilweise mit einem organischen Bindemittel und mit wenigstens einem Flammschutzmittel beschichtet werden, wobei Bindemittel und Flammschutzmittel in Pulverform verwendet werden und wobei die mit Bindemittel und Flammschutzmittel beschichteten schäumbaren und/oder vorgeschäumten Polystyrol-Partikel in eine Form eingegeben und unter Zugabe von Wärme versintert werden, so dass das Bindemittel erweicht und ein zusätzliches Verkleben der Feststoffe bewirkt.Foamable and / or prefoamed polystyrene particles are used in the process proposed for the production of a flame-retardant insulating element, of which at least one part is coated before being filled into a mold and sintered. According to the invention, it is provided that the foamable and / or prefoamed polystyrene particles are at least partially coated with an organic binder and with at least one flame retardant, wherein binders and flame retardants are used in powder form and wherein the foamable and / or prefoamed polystyrene coated with binder and flame retardant Particles in one Form are entered and sintered with the addition of heat, so that the binder softens and causes an additional sticking of the solids.

"In Pulverform" soll bedeuten, dass "trockene" Ausgangsstoffe bzw. Feststoffe zum Beschichten der schäumbaren und/oder vorgeschäumten Polystyrol-Partikel eingesetzt werden. Die pulverförmigen Beschichtungsmittel werden hierzu in Kontakt mit den schäumbaren und/oder vorgeschäumten Polystyrol-Partikeln gebracht, wobei die Oberflächenrauigkeit der schäumbaren und/oder vorgeschäumten Polystyrol-Partikel bereits eine Haftung der Beschichtungsmittel bewirkt."In powder form" is intended to mean that "dry" starting materials or solids are used for coating the foamable and / or prefoamed polystyrene particles. For this purpose, the pulverulent coating compositions are brought into contact with the foamable and / or prefoamed polystyrene particles, wherein the surface roughness of the foamable and / or prefoamed polystyrene particles already brings about adhesion of the coating compositions.

Die pulverförmige Beschichtung kann sowohl auf schäumbare, als auch auf vorgeschäumte Polystyrol-Partikel aufgebracht werden.The powdery coating can be applied to both foamable and prefoamed polystyrene particles.

Bei schäumbaren Polystyrol-Partikeln spricht man allgemein von Polystyrol-Beads, das heißt einem Polystyrol-Granulat, das noch keinem Vorschäumprozess unterzogen wurde. Diese werden zunächst mit pulverförmigen Bindemittel und Flammschutzmittel gemischt und anschließend vorgeschäumt. Die Beschichtung mit Bindemittel und Flammschutzmittel erfolgt vorzugsweise während des Vorschäumens, indem durch Zugabe von Wärme das Bindemittel zum Erweichen gebracht wird. Die sich beim Vorschäumen ausdehnenden Polystyrol-Partikel sowie die Bewegung der Polystyrol-Partikel im Vorschäumbehälter bewirken, dass sich das erweichte Bindemittel um die Partikel legt und das Flammschutzmittel an die Partikel bindet.Foamable polystyrene particles are generally referred to as polystyrene beads, that is to say polystyrene granules which have not yet been subjected to a prefoaming process. These are first mixed with powdered binder and flame retardant and then prefoamed. The coating with binder and flame retardant is preferably carried out during the pre-expansion, by adding the heat, the binder is made to soften. The expansion of the polystyrene particles during prefoaming and the movement of the polystyrene particles in the pre-foaming container cause the softened binder to settle around the particles and bind the flame retardant to the particles.

Alternativ oder ergänzend können bereits vorgeschäumte Polystyrol-Partikel, sogenannte Polystyrol-Perlen, mit Bindemittel und Flammschutzmittel in Pulverform beschichtet und zur weiteren Herstellung eines flammgeschützten Dämmelementes eingesetzt werden.Alternatively or additionally, prefoamed polystyrene particles, so-called polystyrene beads, can be coated with binder and flame retardant in powder form and used for the further production of a flame-retardant insulating element.

Vorzugsweise werden bei Verwendung schäumbarer Polystyrol-Partikel diese nach dem Mischen mit den Beschichtungsmitteln vorgeschäumt bevor sie in eine Form eingebracht und versintert werden. In die Form gelangen demnach beschichtete vorgeschäumte Polystyrol-Partikel, unabhängig davon, ob schäumbare oder vorgeschäumte Polystyrol-Partikel als Ausgangsstoffe verwendet werden. Im Unterschied zu beschichteten vorgeschäumten Polystyrol-Partikeln, die erst vorgeschäumt und dann beschichtet wurden, weisen die Erstgenannten in der Regel eine verbesserte Haftung des Flammschutzmittels an den Polystyrol-Partikeln auf. Denn insbesondere, wenn das Beschichten beim Vorschäumen erfolgt, dringen die zunächst nur oberflächlich anhaftenden pulverförmigen Beschichtungsmittel, insbesondere das Flammschutzmittel, tief in die Oberfläche der expandierenden Polystyrol-Partikel ein. Wird beim Vorschäumen Wasserdampf als Heizmedium eingesetzt, bewirkt die hierbei auftretende Feuchtigkeit ferner ein Verkleben der ursprünglich "trockenen" Ausgangsstoffe. Der als Heizmedium eingesetzte Wasserdampf führt darüber hinaus zu einem Erweichen des Bindemittels, insbesondere, wenn es sich um ein thermoplastisches Bindemittel handelt. Das erweichende und anschließend aushärtende Bindemittel bildet dann eine das Flammschutzmittel zusätzlich bindende Matrix aus. Durch die verbesserte Haftung des Flammschutzmittels an den Polystyrol-Partikeln ist sichergestellt, dass es nicht zu einer Entmischung der Ausgangsstoffe in der Form kommt. Beim nachfolgenden Versintern werden dann Bindemittel und Flammschutzmittel dauerhaft in den Polystyrol-Partikelschaum eingebunden.When foamable polystyrene particles are used, they are preferably prefoamed after mixing with the coating compositions before they are introduced into a mold and sintered. Accordingly, coated prefoamed polystyrene particles enter the mold, regardless of whether foamable or prefoamed polystyrene particles are used as starting materials. In contrast to coated prefoamed polystyrene particles, which were first prefoamed and then coated, the former generally have improved adhesion of the flame retardant to the polystyrene particles. In particular, when the coating takes place during the pre-foaming, the pulverulent coating agents, in particular the flame retardant, which initially adhere only on the surface, penetrate deep into the surface of the expanding polystyrene particles. If water vapor is used as the heating medium during pre-foaming, the moisture that occurs in this case also causes sticking of the originally "dry" starting materials. In addition, the steam used as the heating medium leads to a softening of the binder, especially if it is a thermoplastic binder. The softening and then curing binder then forms a matrix additionally binding the flame retardant. The improved adhesion of the flame retardant to the polystyrene particles ensures that there is no segregation of the starting materials in the mold. During subsequent sintering, binders and flame retardants are permanently incorporated into the polystyrene particle foam.

Der Vorschäumprozess kann kontinuierlich oder diskontinuierlich durchgeführt werden. Erfolgt das Vorschäumen in einem Rührer oder Mischer, trägt die Bewegung zu einer gleichmäßigen Verteilung des Bindemittels und des Flammschutzmittels bei.The prefoaming process can be carried out continuously or discontinuously. If prefoaming takes place in a stirrer or mixer, the movement contributes to a uniform distribution of the binder and the flame retardant.

Die gewählte Formulierung, wonach die Polystyrol-Partikel "zumindest teilweise mit einem organischen Bindemittel und einem Flammschutzmittel beschichtet werden", soll bedeuten, dass vor dem Einbringen der beschichteten vorgeschäumten Polystyrol-Partikel in die Form diesen unbeschichtete vorgeschäumte Polystyrol-Partikel beigemischt werden können. Das heißt, dass ein Teil der verwendeten vorgeschäumten Polystyrol-Partikel auch unbeschichtet bleiben kann. Die Formulierung soll ferner bedeuten, dass alternativ oder ergänzend die Beschichtung mit Bindemittel und Flammschutzmittel lediglich partiell aufgebracht werden kann. In diesem Fall bedeutet "zumindest teilweise beschichtet", dass ein Teil der Polystyrol-Partikel nicht vollflächig beschichtet sein muss, sondern auch unbeschichtete Oberflächenbereiche aufweisen kann.The chosen formulation according to which the polystyrene particles are "at least partially coated with an organic binder and a flame retardant", intended to mean that prior to the introduction of the coated prefoamed polystyrene particles into the mold these uncoated prefoamed polystyrene particles can be mixed. This means that some of the prefoamed polystyrene particles used can also remain uncoated. The formulation should also mean that, alternatively or additionally, the coating with binder and flame retardant can only be applied partially. In this case, "at least partially coated" means that a part of the polystyrene particles need not be coated over the entire surface, but may also have uncoated surface areas.

Der Anteil unbeschichteter und/oder lediglich teilweise beschichteter Polystyrol-Partikel fördert einen Verbund der Partikel untereinander, indem diese - wie bei der Herstellung herkömmlichen Polystyrol-Hartschaums - während des Versinterns miteinander verschmelzen. Dadurch bleibt eine hohe mechanische Stabilität des derart hergestellten Formkörpers erhalten. Ferner wird auf diese Weise der Bindemittelanteil reduziert. Der geringe Bindemittelanteil ermöglicht die Verwendung eines organischen Bindemittels, das gegenüber anorganischen Bindemitteln zwar brennbar ist, dafür aber eine erhöhte Bindekraft besitzt. Dies wirkt sich insbesondere positiv auf die Bindung des Flammschutzmittels an den Polystyrol-Partikeln aus.The proportion of uncoated and / or only partially coated polystyrene particles promotes a bonding of the particles to one another, as they merge together during sintering, as in the case of the production of conventional polystyrene rigid foam. As a result, a high mechanical stability of the molding produced in this way is maintained. Furthermore, in this way the binder content is reduced. The low binder content allows the use of an organic binder, which is combustible compared to inorganic binders, but it has an increased binding power. This has a particularly positive effect on the binding of the flame retardant to the polystyrene particles.

Bevorzugt wird ein Flammschutzmittel zum Beschichten der vorgeschäumten Polystyrol-Partikel verwendet, das im Brandfall eine ablative oder intumeszierende Schutzschicht bildet. Unter einer ablativen Schutzschicht wird vorliegend eine nicht brennbare Schutzschicht verstanden, die "passiv" Feuerwiderstand leistet. Unter einer intumeszierenden Schutzschicht wird eine Schutzschicht verstanden, die erst im Brandfall durch Aufschäumen eine isolierende Schutzschicht ausbildet und demnach "aktiv" Feuerwiderstand leistet. Darüber hinaus können Wasser freisetzende "kühlende" Flammschutzmittel eingesetzt werden, beispielsweise Metallhydroxide, Alkalimetallsilikate sowie Hydrate von Metallsalzen oder -oxiden, die bei erhöhten Temperaturen chemisch oder physikalisch gebundenes Wasser abgeben, im Übrigen aber als "trockenes" Pulver vorliegen. Entsprechende Flammschutzmittel sind hinlänglich bekannt und werden von verschiedenen Herstellern angeboten.Preferably, a flame retardant is used to coat the prefoamed polystyrene particles, which forms an ablative or intumescent protective layer in the event of fire. In the present case, an ablative protective layer is understood to mean a non-flammable protective layer which provides "passive" fire resistance. An intumescent protective layer is understood to mean a protective layer which forms an insulating protective layer only in the event of fire by foaming and accordingly provides "active" fire resistance. In addition, water-releasing "cooling" flame retardants can be used, for example, metal hydroxides, alkali metal silicates and hydrates of metal salts or oxides, which increased at Discharge temperatures chemically or physically bound water, but otherwise present as a "dry" powder. Corresponding flame retardants are well known and are offered by various manufacturers.

Alternativ oder ergänzend wird vorgeschlagen, dass Blähgraphit als Flammschutzmittel verwendet wird. Die flammwidrige Ausstattung der Beschichtung wird durch die Einbindung von Blähgraphit deutlich verbessert. Der Begriff "Blähgraphit" bezeichnet eine synthetisch hergestellte Produktgruppe aus natürlichem Graphit und blähbaren S- und/oder N-Verbindungen, die in die Schichtstruktur des Graphits eingelagert werden. Letztere expandieren unter Einfluss von Hitze, so dass eine aktive Brandbarriere aufgebaut wird. Die Blährate kann dabei bis um das Mehrhundertfache des ursprünglichen Volumens des Blähgraphits betragen.Alternatively or additionally, it is proposed that expanded graphite is used as a flame retardant. The flame-resistant equipment of the coating is significantly improved by the incorporation of expanded graphite. The term "expandable graphite" denotes a synthetically produced product group of natural graphite and expandable S and / or N compounds which are incorporated into the layer structure of the graphite. The latter expand under the influence of heat, creating an active fire barrier. The bloom rate can be up to several hundred times the original volume of expandable graphite.

Als organisches Bindemittel wird weiterhin bevorzugt ein Dispersionspulver, beispielsweise ein Dispersionspulver auf Basis von Acrylat, Styrolacrylat, Vinylacetat, Vinylacetat-Ethylen und/oder Vinylchlorid zum Beschichten der Polystyrol-Partikel verwendet. Der geringe Bindemittelanteil ermöglicht den Einsatz organischer und damit brennbarer Bindemittel. Organische Bindemittel weisen gegenüber anorganischen, nicht brennbaren Bindemitteln eine erhöhte Bindekraft auf, so dass der Bindemittelanteil gering gehalten werden kann. Zudem fördert der Einsatz eines thermoplastischen Bindemittels ein Verkleben der Beschichtungsmittel miteinander und mit den Polystyrol-Partikeln, wenn diese unter Zugabe von Wärme vorgeschäumt und/oder versintert werden.As organic binder, it is further preferred to use a dispersion powder, for example a dispersion powder based on acrylate, styrene acrylate, vinyl acetate, vinyl acetate-ethylene and / or vinyl chloride, for coating the polystyrene particles. The low binder content allows the use of organic and thus combustible binder. Organic binders have an increased binding force compared to inorganic, non-combustible binders, so that the binder content can be kept low. In addition, the use of a thermoplastic binder promotes adhesion of the coating compositions with one another and with the polystyrene particles when they are prefoamed and / or sintered with the addition of heat.

Gemäß einer bevorzugten Ausführungsform der Erfindung werden schäumbare Polystyrol-Partikel, d.h. noch nicht vorgeschäumte Polystyrol-Beads, verwendet, die mit pulverförmigem Bindemittel und Flammschutzmittel gemischt und anschließend vorgeschäumt werden. Das Mischen der Ausgangsstoffe kann dabei auch erst im Vorschäumbehälter und/oder während des Vorschäumens erfolgen. Der Vorschäumprozess verbessert die Haftung des Bindemittels und des Flammschutzmittels an den Polystyrol-Partikeln, da das Bindemittel erweicht und das Flammschutzmittel an die Oberfläche der Polystyrol-Partikel bindet. Werden die Ausgangsstoffe während des Vorschäumens gemischt, das heißt bewegt, verteilt sich das erweichte Bindemittel weitgehend gleichmäßig auf der Oberfläche der Polystyrol-Partikel, so dass auf diese Weise eine weitgehende gleichmäßige Beschichtung der Partikel mit Flammschutzmittel gewährleistet ist. Denn das Flammschutzmittel bleibt insbesondere an dem erweichten Bindemittel haften. Die vorteilhafte Bewegung der Ausgangsstoffe kann dadurch bewirkt werden, dass diese beim Vorschäumen zugleich gerührt werden.According to a preferred embodiment of the invention, foamable polystyrene particles, ie not yet prefoamed polystyrene beads, are used, which are mixed with pulverulent binder and flame retardant and then prefoamed. The mixing of the starting materials can also take place only in Vorschäumbehälter and / or during the pre-expansion. Of the Prefoaming process improves the adhesion of the binder and the flame retardant to the polystyrene particles as the binder softens and binds the flame retardant to the surface of the polystyrene particles. If the starting materials are mixed during the pre-foaming, that is moved, the softened binder spreads substantially uniformly on the surface of the polystyrene particles, so that in this way a largely uniform coating of the particles with flame retardants is guaranteed. Because the flame retardant adheres in particular to the softened binder. The advantageous movement of the starting materials can be effected in that they are stirred during pre-foaming at the same time.

Mit dem Vorgang des Mischens kann zugleich die Beschichtung der Polystyrol-Partikel bewirkt werden. Wie bereits erwähnt, kann ferner das Mischen bzw. das Beschichten während des Vorschäumens erfolgen. Demzufolge können die Vorgänge Mischen, Beschichten und Vorschäumen zeitlich zusammen oder auseinander fallen. Dies gilt sowohl in Bezug auf die Verwendung schäumbarer als auch vorgeschäumter Polystyrol-Partikel.The process of mixing can at the same time effect the coating of the polystyrene particles. As already mentioned, mixing or coating can also take place during pre-foaming. As a result, the operations of mixing, coating and pre-foaming may coincide or disintegrate. This applies both with regard to the use of foamable and prefoamed polystyrene particles.

Gemäß einer weiteren bevorzugten Ausführungsform der Erfindung werden bereits vorgeschäumte Polystyrol-Partikel verwendet und mit pulverförmigem Bindemittel und Flammschutzmittel gemischt. Dabei können auch solche vorgeschäumten Polystyrol-Partikel zum Einsatz gelangen, die noch eine gewisse Restfeuchte vom Vorschäumen aufweisen. Dies hat den Vorteil, dass die pulverförmigen Beschichtungsmittel nicht allein über die Oberflächenrauigkeit der Partikel an diesen haften, sondern ferner über die in den Partikeln enthaltene Restfeuchte gebunden werden. Ergänzend können die bereits vorgeschäumten Polystyrol-Partikel einem weiteren Vorschäumprozess unterzogen werden, bei welchem das anhaftende Bindemittel erweicht und das Flammschutzmittel an die Polystyrol-Partikel bindet.According to a further preferred embodiment of the invention, prefoamed polystyrene particles are already used and mixed with pulverulent binder and flame retardant. In this case, such pre-expanded polystyrene particles can be used, which still have a certain residual moisture from pre-foaming. This has the advantage that the powdery coating compositions do not adhere to them solely via the surface roughness of the particles, but are also bound by the residual moisture contained in the particles. In addition, the already pre-expanded polystyrene particles can be subjected to a further pre-foaming process in which the adhering binder softens and binds the flame retardant to the polystyrene particles.

Bei Anwendung eines erfindungsgemäßen Verfahrens werden zunächst sämtliche Ausgangsstoffe "trocken" (von einer etwaigen, in den vorgeschäumten Polystyrol-Partikeln enthaltenen Restfeuchte abgesehen) zusammengegeben und innig gemischt, wobei das Mischen in einem Vorschäumbehälter und/oder beim Vorschäumen erfolgen kann. Die sich dabei an der Oberfläche der Polystyrol-Partikel ablagernden pulverförmigen Beschichtungsmittel werden durch das Vorschäumen und/oder das Erweichen des Bindemittels an die Polystyrol-Partikel gebunden.When using a method according to the invention, all starting materials "dry" (apart from any residual moisture present in the prefoamed polystyrene particles) are first of all combined and intimately mixed, the mixing taking place in a pre-foaming container and / or during prefoaming. The powdery coating agents deposited on the surface of the polystyrene particles are bound to the polystyrene particles by prefoaming and / or softening the binder.

In Abhängigkeit von den Gewichtsanteilen der verwendeten Ausgangsstoffe können die Polystyrol-Partikel nach dem Mischen und Vorschäumen vollständig oder nur partiell mit Bindemittel und Flammschutzmittel beschichtet sein. Um lediglich partiell beschichtete vorgeschäumte Polystyrol-Partikel zu erhalten, können die pulverförmigen Beschichtungsmittel vor dem Vorschäumen auch durch Aufstreuen oder dergleichen in Kontakt mit den Polystyrol-Partikeln gebracht werden, die dann anschließend vorgeschäumt werden.Depending on the proportions by weight of the starting materials used, the polystyrene particles may be completely or only partially coated with binder and flame retardant after mixing and pre-foaming. To obtain only partially coated prefoamed polystyrene particles, the powdery coating compositions can also be brought into contact with the polystyrene particles by pre-foaming or by sprinkling or the like, which are then subsequently prefoamed.

Ferner wird vorgeschlagen, dass die schäumbaren und/oder vorgeschäumten Polystyrol-Partikel, nachdem sie mit Bindemittel und Flammschutzmittel beschichtet wurden, in eine Form eingegeben und unter Zugabe von Druck und Wärme versintert werden. Durch das nochmalige Aufschäumen und Verschweißen der Polystyrol-Partikel ist sichergestellt, dass das Flammschutzmittel in dem Polystyrol-Partikelschaum fest eingebunden ist. Hierzu leistet auch das Bindemittel einen Beitrag, da dieses bei der Zugabe von Wärme erweicht und ein zusätzliches Verkleben der Feststoffe bewirkt.It is also proposed that the foamable and / or pre-expanded polystyrene particles, after being coated with binder and flame retardant, are introduced into a mold and sintered with the addition of pressure and heat. The repeated foaming and welding of the polystyrene particles ensures that the flame retardant is firmly bound in the polystyrene particle foam. The binder also contributes to this, since it softens with the addition of heat and causes an additional sticking of the solids.

Sofern schäumbare Polystyrol-Partikel verwendet werden, die vor dem Versintern mit Bindemittel und Flammschutzmittel beschichtet werden, kann auch der Zwischenschritt des Vorschäumens entfallen, so dass diese nur einem Schäumprozess unterzogen werden.If foamable polystyrene particles are used, which are coated with binder and flame retardant prior to sintering, the intermediate step of pre-foaming can also be dispensed with, so that these are subjected to only one foaming process.

Gemäß einer bevorzugten Ausführungsform der Erfindung werden den mit Bindemittel und Flammschutzmittel beschichteten schäumbaren und/oder vorgeschäumten Polystyrol-Partikeln vor dem Eingeben in eine Form unbeschichtete Polystyrol-Partikel beigemischt. Die Beimischung unbeschichteter Polystyrol-Partikel - wie auch die Beimischung oder ausschließliche Verwendung lediglich partiell beschichteter Polystyrol-Partikel - fördert ein Verschmelzen der Polystyrol-Partikel miteinander. Wie bereits erwähnt, bewirkt das Verschmelzen bzw. Versintern einen stabilen Verbund der Polystyrol-Partikel untereinander, so dass ein derart hergestelltes Dämmelement eine hohe mechanische Festigkeit aufweist. Vorteilhafterweise beträgt der Anteil der unbeschichteten Polystyrol-Partikel 0 bis 99 Vol.-%, vorzugsweise 25 bis 90 Vol.-% und besonders bevorzugt 50 bis 88 Vol.-% bezogen auf das Gesamtvolumen der verwendeten Polystyrol-Partikel.According to a preferred embodiment of the invention, the foamable and / or prefoamed polystyrene particles coated with binder and flame retardant are admixed with uncoated polystyrene particles before being introduced into a mold. The addition of uncoated polystyrene particles - as well as the admixture or exclusive use of only partially coated polystyrene particles - promotes a fusion of the polystyrene particles together. As already mentioned, the melting or sintering effects a stable bonding of the polystyrene particles to one another, so that an insulating element produced in this way has a high mechanical strength. Advantageously, the proportion of uncoated polystyrene particles 0 to 99 vol .-%, preferably 25 to 90 vol .-% and particularly preferably 50 to 88 vol .-% based on the total volume of the polystyrene particles used.

Die Beimischung unbeschichteter Polystyrol-Partikel bewirkt eine Erhöhung des Polystyrol-Anteils, so dass ein nach diesem Verfahren hergestellter Polystyrol-Partikelschaum sehr gute Wärmedämmeigenschaften - vergleichbar denen herkömmlicher Polystyrol-Schaumstoffe - aufweist. Im Unterschied zu diesen besitzt der nach einem erfindungsgemäßen Verfahren hergestellte Polystyrol-Partikelschaum jedoch zugleich eine erhöhte Brandbeständigkeit. Die erhöhte Brandbeständigkeit wird selbst bei einer Beschichtung mit organischem brennbarem Bindemittel erreicht, da der Bindemittelanteil insgesamt relativ gering ist.The addition of uncoated polystyrene particles causes an increase in the polystyrene content, so that a polystyrene particle foam produced by this process has very good thermal insulation properties - comparable to those of conventional polystyrene foams. In contrast to these, however, the polystyrene particle foam produced by a process according to the invention also has an increased fire resistance. The increased fire resistance is achieved even with a coating with organic combustible binder, since the binder content is relatively low overall.

Versuche an Probekörpern haben überraschenderweise gezeigt, dass eine erhöhte Zugabe von Bindemitteln und/oder Flammschutzmitteln nicht zwangsläufig auch zu einer erhöhten Brandbeständigkeit des Dämmelementes führt. Insbesondere mit zunehmender Menge an Bindemittel - unabhängig davon, ob brennbar oder nicht brennbar - besteht die Gefahr, dass die Brandbeständigkeit abnimmt. Dies liegt darin begründet, dass das Bindemittel Stege zwischen den Polystyrol-Partikeln ausbildet, welche im Brandfall gleichsam als "Docht" wirken, entlang dessen sich ein Feuer ausbreiten kann. Derartige Bindemittelstege unterstützen demnach die Brandausbreitung. Insofern gilt es, die Ausbildung solcher Bindemittelstege zu verhindern, was insbesondere dann gelingt, wenn der Bindemittelanteil möglichst gering gehalten wird.Experiments on specimens have surprisingly shown that an increased addition of binders and / or flame retardants does not necessarily lead to increased fire resistance of the insulating element. In particular, with increasing amount of binder - regardless of whether combustible or non-combustible - there is a risk that the fire resistance decreases. This is due to the fact that the binder forms webs between the polystyrene particles, which act as a "wick" in case of fire, along which a fire can spread. Such binder webs thus support the Fire spread. In this respect, it is important to prevent the formation of such binder webs, which is particularly successful when the binder content is minimized.

Gemäß einer bevorzugten Ausführungsform der Erfindung werden 30 bis 95 Gew.-% schäumbare und/oder vorgeschäumte Polystyrol-Partikel, 0,5 bis 67,5 Gew.-% Bindemittel und 2,5 bis 67,5 Gew.-% Flammschutzmittel, vorzugsweise 40 bis 90 Gew.-% Polystyrol-Partikel, 2,5 bis 55 Gew.-% Bindemittel und 5 bis 55 Gew.-% Flammschutzmittel, weiterhin vorzugsweise 50 bis 85 Gew.-% Polystyrol-Partikel, 5 bis 35 Gew.-% Bindemittel und 7,5 bis 35 Gew.-% Flammschutzmittel, bezogen auf das Gesamtgewicht der Ausgangsstoffe verwendet. Da nur "trockene" Ausgangsstoffe verwendet werden, entspricht das Gesamtgewicht dem Trockengesamtgewicht der Ausgangsstoffe. Um einen Dämmstoff mit hervorragenden Wärmedämmeigenschaften zu erhalten, liegt der Gewichtsanteil der Polystyrol-Partikel besonders bevorzugt bei mindestens 76 Gew.-% bezogen auf das Gesamtgewicht der Ausgangsstoffe.According to a preferred embodiment of the invention, from 30 to 95% by weight of foamable and / or prefoamed polystyrene particles, from 0.5 to 67.5% by weight of binder and from 2.5 to 67.5% by weight of flame retardant, are preferred 40 to 90% by weight of polystyrene particles, 2.5 to 55% by weight of binder and 5 to 55% by weight of flame retardant, furthermore preferably 50 to 85% by weight of polystyrene particles, 5 to 35% by weight % Binder and 7.5 to 35 wt .-% flame retardant, based on the total weight of the starting materials used. Since only "dry" starting materials are used, the total weight corresponds to the total dry weight of the starting materials. In order to obtain an insulating material with excellent thermal insulation properties, the proportion by weight of the polystyrene particles is particularly preferably at least 76 wt .-% based on the total weight of the starting materials.

Gemäß einer weiteren bevorzugten Ausführungsform der Erfindung beträgt das Gewichtsverhältnis der schäumbaren und/oder vorgeschäumten Polystyrol-Partikel zum Flammschutzmittel 0,4 bis 38, vorzugsweise 0,75 bis 34, weiterhin vorzugsweise 1,05 bis 20. Versuche mit entsprechend hergestellten Dämmelementen haben gezeigt, dass diese eine besonders erhöhte Brandbeständigkeit bzw. verringerte Entzündungsneigung aufweisen.According to a further preferred embodiment of the invention, the weight ratio of the foamable and / or prefoamed polystyrene particles to the flame retardant is from 0.4 to 38, preferably from 0.75 to 34, more preferably from 1.05 to 20. Tests with correspondingly produced insulating elements have shown that these have a particularly increased fire resistance or reduced tendency to ignite.

Gemäß einer Weiterbildung der Erfindung werden den beschichteten und/oder unbeschichteten Polystyrol-Partikeln vor dem Eingeben in die Form Fasern, Füllstoffe und/oder Additive zugegeben. Durch die Zugabe von Fasern, Füllstoffen und/oder Additiven können die stoffspezifischen Eigenschaften des Dämmelementes beeinflusst werden. So kann beispielsweise durch die Zugabe von Fasern die mechanische Festigkeit des Dämmelementes erhöht werden.According to one embodiment of the invention, the coated and / or uncoated polystyrene particles are added to fibers, fillers and / or additives before being introduced into the mold. The addition of fibers, fillers and / or additives can influence the substance-specific properties of the insulating element. For example, by adding fibers, the mechanical strength of the insulating element can be increased.

Das vorstehend beschriebene erfindungsgemäße Verfahren weist den Vorteil auf, dass die bislang zur Herstellung von Dämmelementen aus Polystyrol-Hartschaum eingesetzten Anlagen weiterhin eingesetzt werden können. D.h., dass keine neue Anlagentechnik erforderlich ist, so dass das erfindungsgemäße Verfahren kostengünstig durchführbar ist. Insbesondere können die bekannten Blockschäumanlagen sowie Formteilautomaten eingesetzt werden.The process according to the invention described above has the advantage that the systems previously used for the production of insulating elements made of polystyrene rigid foam can continue to be used. This means that no new system technology is required, so that the inventive method is inexpensive to carry out. In particular, the known block foam plants and automatic molding machines can be used.

Vorgeschlagen wird ferner ein Dämmelement, das nach einem der vorhergehenden Verfahren hergestellt worden, wasserundurchlässig und wasserdampfdiffusionsoffen ist. Ein solches Dämmelement nimmt kein Wasser auf, behindert aber die Wasserdampfdiffusion nicht. Es ist demnach insbesondere im Außenbereich oder in feuchtigkeitsbelasteten Innenräumen als Schall- und/oder Wärmedämmelement einsetzbar. Die Wasserundurchlässigkeit des Dämmelementes ist bevorzugt Folge des Versinterns unter Zugabe von Druck und Wärme, bei welchem die zwischen den Partikeln verbleibenden Zwickelräume voneinander isoliert werden. Denn beim Versintern unter Zugabe von Druck und Wärme werden die Ausgangsstoffe durch Druckzunahme in der Form verdichtet. Der Druck kann dabei von Außen aufgebracht und/oder dadurch erzeugt, werden, dass die Polystyrol-Partikel den Drang haben sich auszudehnen. Dabei drängen sich die Polystyrol-Partikel dicht aneinander und verformen sich derart, dass das Zwickelvolumen zwischen den Partikeln reduziert und zugleich isoliert wird.Further proposed is an insulating element which has been produced by one of the preceding methods, impermeable to water and permeable to water vapor. Such an insulating element does not absorb water, but does not hinder the diffusion of water vapor. Accordingly, it can be used, in particular, outdoors or in moisture-laden interior spaces as a sound and / or thermal insulation element. The water impermeability of the insulating element is preferably the result of sintering with the addition of pressure and heat, in which the interstices remaining between the particles are isolated from each other. Because during sintering with the addition of pressure and heat, the starting materials are compressed by increasing the pressure in the mold. The pressure can be applied from the outside and / or generated thereby, that the polystyrene particles have the urge to expand. At the same time, the polystyrene particles crowd close to each other and deform in such a way that the gusset volume between the particles is reduced and at the same time isolated.

Schließlich wird die Verwendung eines nach einem erfindungsgemäßen Verfahren hergestellten Dämmelementes zur Schall- und/oder Wärmedämmung einer Gebäudewand oder -decke vorgeschlagen. Hierin ist die bevorzugte Verwendung eines solchen Dämmelementes zu sehen, da hierbei die besonderen Eigenschaften, insbesondere die erhöhte Brandbeständigkeit unter Beibehaltung der sehr guten Wärmedämmeigenschaften, besonders gut zum Tragen kommen. Ferner wird den hohen Brandschutzanforderungen im Baubereich Rechnung getragen.Finally, the use of an insulating element produced by a method according to the invention for sound and / or thermal insulation of a building wall or ceiling is proposed. Herein, the preferred use of such an insulating element is to be seen, since in this case the special properties, in particular the increased fire resistance while maintaining the very good thermal insulation properties, come particularly well. Furthermore, the high fire protection requirements in the construction sector are taken into account.

Das erfindungsgemäße Verfahren sowie hiernach hergestellte Dämmelemente werden nachfolgend anhand von Beispielen näher beschrieben.The method according to the invention and the insulation elements produced hereafter are described in more detail below with reference to examples.

Allen Beispielen gemein ist, dass herkömmliche schäumbare, d.h. noch nicht vorgeschäumte Polystyrol-Beads verwendet wurden, wie sie zurzeit von diversen Herstellern angeboten werden. In den Beispielen 1 und 2 sowie im Referenzbeispiel kamen die gleichen EPS-Beads zum Einsatz.Common to all examples is that conventional foamable, i. not pre-expanded polystyrene beads were used, as currently offered by various manufacturers. In Examples 1 and 2 and in the Reference Example, the same EPS beads were used.

In einem ersten Schritt wurden die EPS-Beads mit einem Dispersionspulver und einem Flammschutzmittel gemischt und anschließend unter Zugabe von Druck (1 bar) und Wärme (100°C), wobei Wasserdampf als Heizmedium diente, vorgeschäumt. Dabei erweichte das Dispersionspulver und band das Flammschutzmittel in die Bindemittelmatrix ein. Anschließend wurden die beschichteten und vorgeschäumten EPS-Perlen in einem Fließbetttrockner getrocknet (Verweildauer ca. 15 min.), wobei warme Luft als Trocknungsmedium diente. Dabei härteten sowohl die EPS-Perlen, als auch das erweichte Bindemittel aus.In a first step, the EPS beads were mixed with a dispersion powder and a flame retardant and then prefoamed with the addition of pressure (1 bar) and heat (100 ° C), with steam as the heating medium. In the process, the dispersion powder softened and bound the flame retardant into the binder matrix. Subsequently, the coated and prefoamed EPS beads were dried in a fluid bed dryer (residence time about 15 minutes), with warm air serving as the drying medium. This hardened both the EPS beads, as well as the softened binder.

In einem zweiten Schritt wurden den beschichteten und vorgeschäumten EPS-Perlen unbeschichtete herkömmliche EPS-Perlen (Korngröße 3 - 8 mm, Schüttdichte 0,015 - 0,016 g/cm3) beigemischt. Die Mischung wurden dann in eine Form der Abmessung 30 cm x 30 cm x 10 cm eingegeben und unter Zugabe von Druck (1 bar) und Wärme (100°C), wobei wiederum Wasserdampf als Heizmedium diente, der die Form von oben nach unten 10 - 15 Sekunden lang flächig durchströmte, verblockt. Nach dem Druckabbau wurde das Formteil aus der Form genommen und über einen Zeitraum von einer Woche bei Raumtemperatur getrocknet.In a second step, uncoated conventional EPS beads (grain size 3-8 mm, bulk density 0.015-0.016 g / cm 3 ) were added to the coated and prefoamed EPS beads. The mixture was then placed in a mold measuring 30 cm × 30 cm × 10 cm and, with the addition of pressure (1 bar) and heat (100 ° C.), again using steam as the heating medium, the shape from top to bottom 10 - Flowed flat over 15 seconds, blocked. After depressurization, the molded article was removed from the mold and dried at room temperature for a period of one week.

Beispiel 1example 1

Es wurden 56 Gew.-% EPS-Beads mit 12,5 Gew.-% Dispersionspulver (Basis Vinylacetat-Ethylen) und 31,5 Gew.-% Blähgraphit gemischt und - wie zuvor beschrieben - vorgeschäumt. 10 Vol.-% der derart hergestellten beschichteten vorgeschäumten EPS-Perlen wurden dann mit 90 Vol.-% unbeschichteten vorgeschäumten EPS-Perlen homogen vermischt und in der Blockform - wie zuvor beschrieben - versintert und getrocknet.56% by weight of EPS beads containing 12.5% by weight of dispersion powder (based on vinyl acetate-ethylene) and 31.5% by weight of expandable graphite were mixed and, as described above, prefoamed. 10% by volume of the coated prefoamed EPS beads produced in this way were then homogeneously mixed with 90% by volume of uncoated prefoamed EPS beads and sintered in the block mold as described above and dried.

Das derart hergestellte Formteil wies eine Wärmeleitfähigkeit λ nach DIN EN 12667 von 0,0299 W/(mK) und eine Dichte p nach DIN EN 1602 von 16,9 kg/m3 sowie eine Zugfestigkeit senkrecht zur Plattenoberfläche nach DIN EN 1607 von 154 kPa auf. Ferner wurde das Brandverhalten des Formteils getestet, wobei das Formteil zur Beurteilung der Brennbarkeit und des Brandverhaltens einer rauschenden Bunsenbrennerflamme ausgesetzt wurde. Das Testverfahren zeigte ein deutlich vermindertes thermoplastisches Fließen der Schmelze. Die Bildung eines Polymersees war lokal begrenzt. Ein brennendes Abtropfen sowie ein selbständiges Weiterbrennen der Schmelze waren stark vermindert.The molding produced in this way had a thermal conductivity λ according to DIN EN 12667 of 0.0299 W / (mK) and a density p according to DIN EN 1602 of 16.9 kg / m 3 and a tensile strength perpendicular to the plate surface according to DIN EN 1607 of 154 kPa on. Furthermore, the fire behavior of the molded part was tested, wherein the molded part was exposed to a flammable Bunsenbrennerflamme to assess the flammability and the fire behavior. The test procedure showed a significantly reduced thermoplastic melt flow. The formation of a polymer lake was localized. A burning dripping and an independent further burning of the melt were greatly reduced.

Beispiel 2Example 2

Es wurden 56 Gew.-% EPS-Beads mit 12,5 Gew.-% Dispersionspulver (Basis Polyvinylalkohol) und 31,5 Gew.-% Blähgraphit gemischt und - wie zuvor beschrieben - vorgeschäumt. 40 Vol.-% der derart hergestellten beschichteten vorgeschäumten EPS-Perlen wurden dann mit 60 Vol.-% unbeschichteten vorgeschäumten EPS-Perlen homogen vermischt und in der Blockform - wie zuvor beschrieben - versintert und getrocknet.56% by weight of EPS beads with 12.5% by weight of dispersion powder (based on polyvinyl alcohol) and 31.5% by weight of expandable graphite were mixed and, as described above, prefoamed. 40% by volume of the coated prefoamed EPS beads produced in this way were then mixed homogeneously with 60% by volume of uncoated prefoamed EPS beads and sintered in the block mold as described above and dried.

Das derart hergestellte Formteil wies eine Wärmeleitfähigkeit λ nach DIN EN 12667 von 0,0307 W/(mK) und eine Dichte p nach DIN EN 1602 von 20,2 kg/m3 sowie eine Zugfestigkeit senkrecht zur Plattenoberfläche nach DIN EN 1607 von 166 kPa auf. Ferner wurde das Brandverhalten des Formteils getestet, wobei das Formteil zur Beurteilung der Brennbarkeit und des Brandverhaltens einer rauschenden Bunsenbrennerflamme ausgesetzt wurde. Das Testverfahren zeigte kein thermoplastisches Fließen der Schmelze. Ein brennendes Abtropfen fand nicht statt. Ferner konnte ein selbstständiges Weiterbrennen des Prüfkörpers nach Entfernen der Flamme vollständig unterbunden werden.The molded part produced in this way had a thermal conductivity λ according to DIN EN 12667 of 0.0307 W / (mK) and a density p according to DIN EN 1602 of 20.2 kg / m 3 and a tensile strength perpendicular to the plate surface according to DIN EN 1607 of 166 kPa on. Furthermore, the fire behavior of the molded part was tested, wherein the molded part for Assessment of the flammability and the fire behavior of a roaring Bunsenbrennerflamme was exposed. The test procedure did not show thermoplastic melt flow. A burning dripping did not take place. Furthermore, an independent further burning of the test piece after removal of the flame could be completely prevented.

Referenzbeispielreference example

Es wurden 9 Liter unbeschichtete vorgeschäumte EPS-Perlen (Korngröße 3 - 8 mm, Schüttdichte 0,015 - 0,16 g/cm3) in eine Form der Abmessungen 30 cm x 30 cm x 10 cm eingegeben und unter Zugabe von Druck (1 bar) und Wärme (100°C), wobei Wasserdampf als Heizmedium diente, der die Form 10 - 15 Sekunden lang von oben nach unten flächig durchströmte, verblockt. Nach dem Druckabbau wurde das Formteil aus der Form genommen und über einen Zeitraum von einer Woche bei Raumtemperatur getrocknet.9 liters of uncoated prefoamed EPS beads (grain size 3 - 8 mm, bulk density 0.015 - 0.16 g / cm 3 ) were introduced into a mold measuring 30 cm × 30 cm × 10 cm and added with pressure (1 bar) and heat (100 ° C), with steam as the heating medium, which flowed through the form from top to bottom for 10 to 15 seconds. After depressurization, the molded article was removed from the mold and dried at room temperature for a period of one week.

Das derart hergestellte Formteil wies eine Wärmeleitfähigkeit λ nach DIN EN 12667 von 0,0297 W/(mK) und eine Dichte p nach DIN EN 1602 von 15,8 kg/m3 sowie eine Zugfestigkeit senkrecht zur Plattenoberfläche nach DIN EN 1607 von 173 kPa auf. Ferner wurde das Brandverhalten des Formteils getestet, wobei das Formteil zur Beurteilung der Brennbarkeit und des Brandverhaltens einer rauschenden Bunsenbrennerflamme ausgesetzt wurde. Das Testverfahren zeigte ein sofortiges thermoplastisches Schmelzen mit brennendem Abtropfen, was die Bildung eines brennenden Polymersees zur Folge hatte.The molded part produced in this way had a thermal conductivity λ according to DIN EN 12667 of 0.0297 W / (mK) and a density p according to DIN EN 1602 of 15.8 kg / m 3 and a tensile strength perpendicular to the plate surface according to DIN EN 1607 of 173 kPa on. Furthermore, the fire behavior of the molded part was tested, wherein the molded part was exposed to a flammable Bunsenbrennerflamme to assess the flammability and the fire behavior. The test procedure showed immediate thermoplastic melting with burning dripping which resulted in the formation of a burning polymer lake.

Ein nach einem erfindungsgemäßen Verfahren hergestelltes Dämmelement (Beispiele 1 und 2) weist demnach gegenüber einem herkömmlichen Dämmelement aus Polystyrol-Hartschaum (Referenzbeispiel) ein deutlich verbessertes Brandverhalten auf. Aufgrund einer nicht mehr fließfähigen Schmelze bzw. eines stark verminderten Fließverhaltens bleibt der Brandherd lokal begrenzt. Insbesondere bildet sich kein brennender Polymersee. Zugleich weisen die nach einem erfindungsgemäßen Verfahren hergestellten Dämmelemente weiterhin sehr gute Wärmedämmeigeneschaften sowie eine hohe mechanische Festigkeit auf.An insulating element produced by a process according to the invention (Examples 1 and 2) accordingly has a significantly improved fire behavior compared to a conventional insulating element made of polystyrene rigid foam (Reference Example). Due to a no longer flowable melt or a greatly reduced flow behavior, the source of the fire remains localized. Especially no burning polymer lake forms. At the same time, the insulating elements produced by a method according to the invention continue to have very good thermal insulation properties and high mechanical strength.

Claims (12)

  1. A method for producing a flame-retardant insulating element, in which foamable and/or pre-foamed polystyrene particles are used, of which at least some are coated before filling into a mould and sintering,
    characterised in that the foamable and/or pre-foamed polystyrene particles are coated at least in part with an organic binder and a flame retardant, wherein binder and flame retardant are used in powder form, and wherein the foamable and/or pre-foamed polystyrene particles coated with binder and flame retardant are introduced into a mould and are sintered under addition of heat, such that the binder softens and causes an additional bonding of the solids.
  2. The method according to Claim 1,
    characterised in that a flame retardant that forms an ablative or intumescent protective layer in the event of a fire is used to coat the pre-foamed polystyrene particles, and/or in that expandable graphite is used as flame retardant.
  3. The method according to Claim 1 or 2,
    characterised in that a dispersion powder, for example a dispersion powder based on acrylate, styrene acrylate, vinyl acetate, vinyl acetate ethylene and/or vinyl chloride, is used as organic binder for coating the polystyrene particles.
  4. The method according to one of the preceding claims, characterised in that foamable polystyrene particles are mixed with the binder and the flame retardant in powder form and are then pre-foamed.
  5. The method according to one of the preceding claims,
    characterised in that pre-foamed polystyrene particles are mixed with the binder and/or the flame retardant in powder form.
  6. The method according to one of the preceding claims,
    characterised in that the foamable and/or pre-foamed polystyrene particles coated with binder and flame retardant are introduced into a mould and are sintered with addition of pressure and heat.
  7. The method according to one of the preceding claims,
    characterised in that the foamable and/or pre-foamed polystyrene particles coated with binder and flame retardant are admixed with polystyrene particles prior to the introduction into a mould, wherein the proportion of the uncoated polystyrene particles is preferably 0 to 99 vol. %, more preferably 25 to 90 vol. %, and particularly preferably 50 to 88 vol. %, in relation to the total volume of the polystyrene particles used.
  8. The method according to one of the preceding claims,
    characterised in that 30 to 95 % by weight of foamable and/or pre-foamed polystyrene particles, 0.5 to 67.5 % by weight of binder and 2.5 to 67.5 % by weight of flame retardant, preferably 40 to 90 % by weight of polystyrene particles, 2.5 to 55 % by weight of binder and 5 to 55 % by weight of flame retardant, more preferably 50 to 85 % by weight of polystyrene particles, 5 to 35 % by weight of binder and 7.5 to 35 % by weight of flame retardant, are used in relation to the total weight of the starting materials.
  9. The method according to one of the preceding claims,
    characterised in that the ratio by weight of the foamable and/or pre-foamed polystyrene particles to the flame retardant is 0.4 to 38, preferably 0.75 to 34, more preferably 1.05 to 20.
  10. The method according to one of the preceding claims,
    characterised in that fibres, fillers and/or additives are added to the coated and/or uncoated polystyrene particles prior to the introduction into the mould.
  11. An insulating element that has been produced in accordance with one of the preceding methods and is impermeable to water and is open to steam diffusion.
  12. Use of an insulating element that has been produced in accordance with one of the preceding methods for sound insulation and/or heat insulation of a building wall or ceiling.
EP12184184.5A 2012-09-13 2012-09-13 Method for producing a flame retardant insulating element, insulating element and use of an insulating element Active EP2708668B1 (en)

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DK12184184.5T DK2708668T3 (en) 2012-09-13 2012-09-13 Process for producing a fire-retardant insulating element, insulating element and using an insulating element
EP12184184.5A EP2708668B1 (en) 2012-09-13 2012-09-13 Method for producing a flame retardant insulating element, insulating element and use of an insulating element
PL12184184T PL2708668T3 (en) 2012-09-13 2012-09-13 Method for producing a flame retardant insulating element, insulating element and use of an insulating element

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP12184184.5A EP2708668B1 (en) 2012-09-13 2012-09-13 Method for producing a flame retardant insulating element, insulating element and use of an insulating element

Publications (2)

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EP2708668A1 EP2708668A1 (en) 2014-03-19
EP2708668B1 true EP2708668B1 (en) 2014-12-31

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EP12184184.5A Active EP2708668B1 (en) 2012-09-13 2012-09-13 Method for producing a flame retardant insulating element, insulating element and use of an insulating element

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PL (1) PL2708668T3 (en)

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN103980624B (en) * 2014-05-19 2016-05-25 四川大学 Halogen-free flameproof polystyrene foam composite material and preparation method thereof
DE102023130368A1 (en) * 2023-11-02 2025-05-08 T Chesa GmbH Structural buildings for self-construction

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
ZA838457B (en) * 1982-11-15 1984-09-26 Dixon International Ltd Flame-resistant expanded plastics material
DE19845891A1 (en) * 1998-10-06 2000-04-20 Schwenk Daemmtechnik Gmbh & Co Foams based on polystyrene
RU2470042C2 (en) 2007-05-30 2012-12-20 Инеос Нова Интернэшнл Са Fire-resistant polystyrene
EP2158258A4 (en) * 2007-05-30 2011-10-05 Jae-Cheon Kim Expandable polystyrene bead with superior adiabatic and flameproof effect and method for producing the same

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PL2708668T3 (en) 2015-05-29
DK2708668T3 (en) 2015-02-09
EP2708668A1 (en) 2014-03-19

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